Zippered mattress cover with inner flange

ABSTRACT

A mattress cover may include a top cover portion, a bottom cover portion, and a border panel cover portion positioned to extend around a perimeter of a mattress. The mattress cover may include a closure element positioned to enable opening of the cover to access an interior region of the cover. The mattress cover includes an internal flange element positioned in the interior region. A mattress may include the cover, and the flange element may be connected to one or more internal mattress elements, such as springs or foam. A method of making a mattress may include positioning internal mattress elements in the interior region, attaching the internal flange element to at least one of internal mattress elements, and closing the mattress cover with a closure element such as a zipper. The closure element may be positioned on a bottom side of the cover.

BACKGROUND

Conventional techniques for assembling a mattress include forming a stack of internal mattress elements, such as springs, padding, gel, or other elements, then forming a separate top cover portion, a separate bottom cover portion, and a separate border panel cover portion. The separate top, bottom, and border panel cover portions are then assembled around the stack of internal elements to form the mattress. The top or bottom cover portions may include a flange element that is connected to the mattress stack (for example, the springs) via a connection element, such as hog rings. The border panel cover portion is attached to the separate top and bottom cover portions by stitching or a tape edge.

The process for assembling the separate cover portions is generally time consuming, unwieldy, and requires specially trained assembly workers who are becoming scarce in the mattress industry. Accordingly, there remains a need for a mattress covering that improves production efficiency, provides traditional aesthetic and comfort features, and provides sufficient support for internal elements.

SUMMARY

Representative embodiments of the present technology may include a mattress cover having a top cover portion, a bottom cover portion, and a border panel cover portion positioned to extend around a perimeter of a mattress. The mattress cover may include a closure element positioned to enable opening of the cover to access an interior region of the cover. The mattress cover includes an internal flange element positioned in the interior region. A mattress may include the cover, and the flange element may be connected to one or more internal mattress elements, such as springs or foam. A method of making a mattress may include positioning internal mattress elements in the interior region, attaching the internal flange element to at least one of internal mattress elements, and closing the mattress cover with a zipper or other closure element. The closure element (such as the zipper) may be positioned on a bottom side of the mattress cover.

Other features and advantages will appear hereinafter. The features described above can be used separately or together, or in various combinations of one or more of them.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, wherein the same reference number indicates the same element throughout the several views:

FIG. 1A illustrates a perspective view of a mattress configured in accordance with embodiments of the present technology.

FIG. 1B illustrates a bottom perspective view of the mattress shown in FIG. 1A.

FIG. 1C illustrates an exploded or unassembled bottom perspective view of the mattress shown in FIGS. 1A and 1B. FIG. 1C also illustrates a schematic view of internal mattress elements.

FIG. 1D illustrates a schematic side cross-sectional view of the mattress cover shown in FIGS. 1A-1C, along with representative internal mattress elements.

FIG. 2 illustrates a schematic side cross-sectional view of a mattress cover configured in accordance with further embodiments of the present technology.

FIG. 3A illustrates a top perspective view of a mattress configured in accordance with further embodiments of the present technology.

FIG. 3B illustrates a bottom perspective view of the mattress shown in FIG. 3A.

FIG. 3C illustrates a schematic side cross-sectional view of the mattress cover shown in FIGS. 3A and 3B, along with representative internal mattress elements.

FIG. 4 illustrates a schematic cross-sectional view of an interface between a flange element, a top cover portion, and a border panel cover portion, configured in accordance with embodiments of the present technology, and suitable for implementation in any embodiment of the present technology in which a tape-edge construction is used to join elements of a mattress cover.

FIG. 5 illustrates a perspective view of a mattress configured in accordance with additional embodiments of the present technology.

DETAILED DESCRIPTION

The present technology is directed to a zippered mattress cover with one or more internal flanges, and associated systems and methods. Various embodiments of the technology will now be described. The following description provides specific details for a thorough understanding and enabling description of these embodiments. One skilled in the art will understand, however, that the invention may be practiced without many of these details. Additionally, some well-known structures (such as internal mattress elements including padding or springs) or functions may not be shown or described in detail so as to avoid unnecessarily obscuring the relevant description of the various embodiments. Accordingly, embodiments of the present technology may include additional elements or exclude some of the elements described below with reference to FIGS. 1-5 , which illustrate examples of the technology.

The terminology used in this description is intended to be interpreted in its broadest reasonable manner, even though it is being used in conjunction with a detailed description of certain specific embodiments of the invention. Certain terms may even be emphasized below; however, any terminology intended to be interpreted in any restricted manner will be overtly and specifically defined as such in this detailed description section.

Where the context permits, singular or plural terms may also include the plural or singular term, respectively. Moreover, unless the word “or” is expressly limited to mean only a single item exclusive from the other items in a list of two or more items, then the use of “or” in such a list is to be interpreted as including (a) any single item in the list, (b) all the items in the list, or (c) any combination of items in the list. Further, unless otherwise specified, terms such as “attached” or “connected” are intended to include integral connections, as well as connections between physically separate components.

FIG. 1A illustrates a top perspective view of a mattress 100 configured in accordance with embodiments of the present technology. The mattress 100 may include a mattress cover 105 (which may be referred to herein as a cover 105) and one or more internal mattress elements positioned within the cover 105, such as springs, one or more layers of foam material, or layers of other material.

The cover 105 may include a top cover portion 110 on a top side of the cover 105, a bottom cover portion 115 (see FIG. 1B), and a border panel cover portion 120 extending around the perimeter of the mattress 100 between the top cover portion 110 and the bottom cover portion 115. The top cover portion 110 may optionally include a quilted region 125 that includes a cushioning material similar to traditional quilted or pillow-top materials on traditional mattresses. The top cover portion 110 may include a “Euro top” arrangement, a “pillow top” arrangement, a “tight top” arrangement, or another suitable arrangement. Accordingly, the top cover portion 110 may optionally include an additional padded section mounted to the top cover portion 110, similar to some conventional mattress arrangements.

In some embodiments, the top cover portion 110 is joined to the border panel cover portion 120 with an upper connection 130, such as stitching, adhesive, or a tape-edge construction. The tape-edge construction may be formed with a tape-edge machine, and it may provide a traditional appearance and feel. In some embodiments, the bottom cover portion 115 is joined to the border panel cover portion 120 with a lower connection 135 such as stitching, adhesive, or a tape-edge construction. The connections 130, 135 may extend along the perimeter of the mattress 100 (around the corresponding perimeters of the top cover portion 110 and the bottom cover portion 115).

FIG. 1B illustrates a bottom perspective view of the mattress 100 shown in FIG. 1A. The bottom cover portion 115 may optionally include a non-skid material. In some embodiments, the bottom side of the mattress (the side with the bottom cover portion 115) includes a closure element 140, such as a zipper. For example, the bottom cover portion 115 may include the closure element 140. The closure element 140 may be positioned such that the lower connection 135 is positioned between the closure element 140 and the border panel cover portion 120. In some embodiments, the closure element 140 is located entirely within the bottom cover portion 115 such that when the mattress 100 is oriented top-up and bottom-down, the closure element 140 may be concealed beneath the mattress 100 to comply with regulations associated with fire resistance (because fire may penetrate zippers or other closure elements, some regulations prohibit zippers or other closure elements from being exposed, such as on a side or top of a mattress). The cover 105 is shown in FIGS. 1A and 1B in a closed configuration.

FIG. 1C illustrates an exploded or unassembled bottom perspective view of the mattress 100 shown in FIGS. 1A and 1B. More specifically, FIG. 1C shows a bottom perspective view of the cover 105 in an open configuration, in accordance with embodiments of the present technology. FIG. 1C also illustrates a schematic view of internal mattress elements 142, which may include foam padding 143, springs 144, or other suitable internal mattress elements 142 that provide structure or cushion to the overall mattress 100 assembly.

The unassembled view of FIG. 1C (in which the reader is viewing into the open bottom of the cover 105) facilitates viewing an interior volume or interior region 145 of the cover 105. When the mattress 100 is assembled, the internal mattress elements 142 are received in the interior region 145 and covered by the cover 105. The closure element 140 may be positioned on the bottom of the cover 105 and configured to be opened and closed to allow access to the interior region 145. In some embodiments, the closure element 140 may be permanently closed, for example, with a hog ring or another permanent closure device.

In some embodiments, the cover 105 includes one or more internal flange elements 150 positioned in the interior region 145. The one or more internal flange elements 150 may extend from a top interface 155 between the top cover portion 110 and the border panel cover portion 120. For example, the one or more internal flange elements 150 may extend inside the interior region 145 from the upper connection 130. Generally, the one or more internal flange elements 150 may be attached to, and extend from, the top cover portion 110, the border panel cover portion 120, the bottom cover portion 115, an interface between the top cover portion 110 and the border panel cover portion 120, or an interface between the bottom cover portion 115 and the border panel cover portion 120.

The one or more internal flange elements 150 may be configured for attachment to one or more of the internal mattress elements 142, such as attachment to the foam padding 143, attachment to the springs 144, or attachment to other internal mattress elements 142 or combinations of internal mattress elements 142. Connecting the flange elements 150 to the internal mattress elements 142 provides a secure connection between the cover 105 and the internal mattress elements 142, while mimicking the look and feel of a traditional mattress without the complications associated with assembling a traditional mattress.

In some embodiments, the internal flange elements 150 may include free ends 160 for attaching the internal flange elements 150 to one or more of the internal mattress elements 142. The one or more internal flange elements 150 may be attached to the one or more internal mattress elements 142 using one or more flange connection elements 165, such as staples, stitching, hog rings, or any other suitable connection devices. In embodiments in which the flange elements 150 connect to foam (such as the foam padding 143), staples may be preferred. In embodiments in which the flange elements 150 connect to springs 144, hog rings may be preferred. Conventional devices for connecting the internal flange elements 150 to the internal mattress elements 142 may be implemented.

Although two internal flange elements 150 are illustrated as being on opposing long sides of the cover 105, in some embodiments, the cover 105 may include a flange element 105 on one or both opposing short sides of the cover 105. In some embodiments, multiple internal flange elements 150, or a single integral internal flange element 150, may extend along some or all of the perimeter of the cover 105. In some embodiments, the cover 105 may include flange elements 150 inside the interior region 145 extending from some, all, or any suitable quantity of the interfaces of the cover 105 between the top cover portion 110 and the border panel cover portion 120, or between the bottom cover portion 115 and the border panel cover portion 120. Accordingly, embodiments of the present technology may include any number or configuration of flange elements 150.

FIG. 1D illustrates a schematic side cross-sectional view of the cover 105 and representative internal mattress elements in the form of springs 144 (although, as described above, the internal mattress elements may additionally or alternatively include other elements). Only a few springs 144 are shown in order to illustrate hog rings 165 connected to the springs 144. Any suitable quantity of springs 144 may be implemented in various embodiments. The border panel cover portion 120 may also include a quilted region similar to the quilted region 125 of the top cover portion, which may help make the cover 105 look and feel like the outside of a traditional mattress. FIG. 1D illustrates the border panel cover portion 120 having such a quilted region.

FIG. 2 illustrates a schematic side cross-sectional view of a cover 200 configured in accordance with additional embodiments of the present technology. As explained above, a cover configured in accordance with embodiments of the present technology may include flange elements 150 extending from some, all, or any suitable quantity of the interfaces between the top cover portion 110 and the border panel cover portion 120, or between the bottom cover portion 115 and the border panel cover portion 120. Accordingly, in some embodiments, the cover 200 includes one or more flange elements 150 extending from the top interface 155, and one or more flange elements 150 extending from a bottom interface 205 between the bottom cover portion 115 and the border panel cover portion 120.

FIG. 3A illustrates a top perspective view of a mattress 300 configured in accordance with further embodiments of the present technology. The mattress 300 may include a mattress cover 305 (which may be referred to herein as a cover 305) and one or more internal mattress elements, such as the internal mattress elements described above, which may include springs, one or more layers of foam material, or layers of other material.

The cover 305 may include the top cover portion 110 described above, a bottom cover portion 315 (see FIG. 3B), and a border panel cover portion 320 extending around the perimeter of the mattress 300 between the top cover portion 110 and the bottom cover portion 315. In some embodiments, the top cover portion 110 is joined to the border panel cover portion 320 with an upper connection 330 such as stitching, adhesive, or a tape-edge construction. The tape-edge construction may provide a traditional appearance and feel. The upper connection 330 may extend along the perimeter of the mattress 300 (around the perimeter of the top cover portion 110).

Accordingly, the mattress 300 and the cover 305 may be generally similar to the mattress 100 and the cover 105 described above with regard to FIGS. 1A-1D, with a difference being that the mattress 300 and the cover 305 may not have a tape-edge connection extending along the lower perimeter 335 of the mattress 300 and the cover 305. Instead, the border panel cover portion 320 may extend beneath the lower perimeter 335 of the mattress 300 to connect to the bottom cover portion 315 with a closure element.

FIG. 3B illustrates a bottom perspective view of the mattress 300 shown in FIG. 3A. The bottom cover portion 315 may optionally include a non-skid material. The border panel cover portion 320 extends beneath the lower perimeter 335 of the mattress 300. In some embodiments, the border panel cover portion 320 is attached to the bottom cover portion 315 at an interface positioned on the bottom side of the mattress (the side having bottom cover portion 315). In some embodiments, the interface joining the border panel cover portion 320 and the bottom cover portion 315 includes a closure element 340, such as a zipper. Accordingly, when the mattress 300 is positioned top-up and bottom-down, the closure element 340 may be concealed to comply with regulations associated with fire resistance. The closure element 340 may be positioned such that the lower perimeter 335 is positioned between the closure element 340 and the border panel cover portion 320.

FIG. 3C illustrates a schematic side cross-sectional view of the cover 305 and representative internal mattress elements in the form of springs 144 (although, as described above, the internal mattress elements may additionally or alternatively include other elements). In some embodiments, the cover 305 may include one or more internal flange elements 150 in a manner similar to the flange elements 150 described above and shown in FIGS. 1-2 . For example, the cover 305 may include one or more internal flange elements 150 extending from an upper interface 355 between the top cover portion 110 and the border panel cover portion 320. In some embodiments, the cover 305 may optionally include one or more internal flange elements 150 extending from a bottom corner 306 of the border panel cover portion 320. For example, one or more of the internal flange elements 150 may be attached to the border panel cover portion 320 adjacent to the location where the border panel cover portion 320 bends from a side of the cover 305 toward the bottom cover portion 315. Hog rings or other suitable flange connection elements 165 may connect the one or more flange elements 150 to the internal mattress elements (such as the springs 144). The border panel cover portion 320 may also include a quilted region similar to the quilted region 125 of the top cover portion, which may help make the cover 305 look and feel like the outside of a traditional mattress. FIG. 3C illustrates the border panel cover portion 320 having such a quilted region.

The cover 305 is shown in FIGS. 3A, 3B, and 3C in a closed configuration. The closure element 340 may be opened to reveal an interior region 145 in a manner similar to opening the cover 105 shown in FIG. 1C.

FIG. 4 illustrates a schematic cross-sectional view of an interface 400 between a flange element 150, a top cover portion 110, and a border panel cover portion 120 or 320, configured in accordance with embodiments of the present technology, and suitable for implementation in any embodiment of the present technology in which a tape-edge construction is used to join elements of a mattress cover. In some embodiments, the interface 400 includes the flange element 150 attached to the top cover portion 110 with serge stitching 405. The border panel cover portion 120, 320 may then be attached to the combined assembly of the flange and the top via a tape-edge connection 410, which may include tape 415 straight stitched 420 to the flange, top, and border. Such an interface 400 provides a traditional aesthetic appearance while implementing aspects of the present technology (such as the flange element 150).

In some embodiments, a method of making a mattress cover (such as any of the covers disclosed herein) may include preparing the top cover portion 110 (for example, by cutting it to size or adding quilting), then stitching (for example, serge stitching) the top cover portion 110 to the flange element 150. In some embodiments, the edge of the top cover portion 110 may be run through a sewing machine that trims and binds the edge while attaching the flange element 150 with the serge stitching. The combination of the top cover portion 110 and the flange element 150 may form a first subassembly. The border panel cover portion 120, 320 may form a second subassembly. The first subassembly and the second subassembly may then be bound together by the tape 415. The combined first subassembly and second subassembly may then be attached to a bottom cover portion 115, 315.

In some embodiments, instead of the flange element 150 being initially attached to the top cover portion 110, the flange element 150 may be attached to the border panel cover portion 120, 320 with serge stitching, to form a first subassembly. Such a first subassembly (formed with the border panel cover portion 120, 320 and the flange element 150) may then be attached to the top cover portion 110 with the tape 415.

FIG. 5 illustrates a perspective view of a mattress 500 configured in accordance with additional embodiments of the present technology. The mattress 500 may be generally similar to other mattresses described above. The mattress 500 may include a cover 505 similar to other covers (e.g., 105, 200, 305) described above. For example, it may include one or more internal flange elements 150 as described above. In some embodiments, however, instead of having a closure element 140 positioned on the bottom side of the mattress, the cover 505 may include a closure element 140 positioned on, and integrated into, the border panel cover portion 120, such that the border panel cover portion 120 can facilitate access to the interior region of the cover 505. The closure element 140 on the border panel cover portion 120 is illustrated schematically in FIG. 5 , and it may extend around some or all of the perimeter of the mattress 500 (for example, it may allow opening one side or multiple sides, or even all sides of the mattress 500). In such embodiments, to meet fire regulations, the mattress 500 may include a fire-resistant sock around some or all of the internal mattress elements 142 (see FIG. 1C). In other embodiments, the closure element 140 can include a fire-resistant cover or other fire-resistant elements to meet fire regulations.

Embodiments of the present technology enable new methods of making or assembling a mattress. Covers (such as the covers 105, 200, 305, 505 described above) may be positioned over internal mattress elements 142, secured to the internal mattress elements 142 via the flange elements 150 in a manner that applies tension to the flange elements 150 and the overall covers, and closed using the closure elements 140.

In some embodiments, a user or installer may reverse the covers to an inside-out configuration to facilitate attaching the flange elements 150 to the internal mattress elements 142 before returning the covers to their normal configuration (not inside-out) and closing them with the closure elements 140. Accordingly, the covers may be pre-made before being attached to the internal mattress elements as opposed to traditional mattress manufacturing methods that may involve attaching portions of a cover (such as a flange) to internal mattress elements before the cover itself is completely assembled or connected. Embodiments of the present technology also provide a mattress cover or mattress assembly that has the look and feel of a traditional mattress, while facilitating quicker installation or assembly without the need for a tape-edge operator when the cover is positioned on the internal mattress elements.

From the foregoing, it will be appreciated that specific embodiments of the presently disclosed technology have been described herein for purposes of illustration, but that various modifications may be made without deviating from the scope of the technology. Although zippers are disclosed for closing the covers, in other embodiments, snaps, buttons, hook-and loop fasteners (such as VELCRO™), adhesive (such as adhesive strips), or other suitable closure devices may be included. Closure elements may be permanently closed such that opening them results in destruction of the mattress cover or the closure element. Some embodiments may omit one or more components. Accordingly, mattresses and mattress covers configured in accordance with embodiments of the present technology may include other combinations of features disclosed herein.

Certain aspects of the technology described in the context of particular embodiments may be combined or eliminated in other embodiments. Further, while advantages associated with certain embodiments of the presently disclosed technology have been described in the context of those embodiments, other embodiments may also exhibit such advantages, and not all embodiments need necessarily exhibit such advantages to fall within the scope of the technology. Accordingly, the disclosure and associated technology can encompass other embodiments not expressly shown or described herein. 

What is claimed is:
 1. A mattress comprising a mattress cover and one or more internal mattress elements positioned within an interior region of the mattress cover, wherein the mattress cover comprises: a top cover portion; a bottom cover portion; a closure element positioned to selectively open or close the mattress cover, wherein the closure element is positioned on a bottom side of the mattress cover; a border panel cover portion extending around a perimeter of the mattress between the top cover portion and the bottom cover portion; and one or more internal flange elements positioned in the interior region of the mattress cover, wherein a free end of the one or more internal flange elements is attached to at least one of the one or more internal mattress elements.
 2. The mattress of claim 1, wherein the one or more internal mattress elements comprises at least one of foam or one or more springs.
 3. The mattress of claim 1, wherein the top cover portion comprises a quilted top portion.
 4. The mattress of claim 1, wherein the border panel cover portion is joined to the top cover portion with a tape edge.
 5. The mattress of claim 4, wherein the border panel cover portion is joined to the bottom cover portion with a tape edge.
 6. The mattress of claim 4, wherein the border panel cover portion extends beneath a lower perimeter of the mattress, and wherein the border panel cover portion is attached to the bottom cover portion at an interface positioned on a bottom side of the mattress.
 7. The mattress of claim 6, wherein the interface comprises the closure element.
 8. The mattress of claim 1 wherein the bottom cover portion comprises a non-skid material.
 9. The mattress of claim 1, wherein the closure element comprises a zipper.
 10. The mattress of claim 1, wherein the one or more internal flange elements extends from an interface between the top cover portion and the border panel cover portion.
 11. The mattress of claim 1, wherein the one or more internal flange elements comprises a single integral internal flange element extending around a perimeter of the mattress cover within the interior region.
 12. The mattress of claim 1, wherein an interface between the top cover portion, the border panel cover portion, and at least one of the one or more internal flange elements comprises: the at least one flange element stitched to the top cover portion; and the border panel cover portion connected to the at least one flange element and the top cover portion via a tape edge connection.
 13. A cover for a mattress, the cover comprising: a top cover portion positioned on a top side of the cover; a bottom cover portion positioned on a bottom side of the cover, opposite the top cover portion; a border panel cover portion positioned to extend around a perimeter of the mattress between the top cover portion and the bottom cover portion, wherein the top cover portion, the bottom cover portion, and the border panel cover portion enclose an interior region of the cover; a closure element positioned to enable opening of the cover to access the interior region, wherein the closure element is positioned on a bottom side of the cover; and an internal flange element positioned in the interior region of the cover, wherein the internal flange element extends from an upper connection between the top cover portion and the border panel cover portion, to a free end of the internal flange element.
 14. The cover of claim 13, wherein the top cover portion comprises a quilted top portion.
 15. The cover of claim 13, wherein the border panel cover portion extends beneath a lower perimeter of the cover, and wherein the border panel cover portion is attached to the bottom cover portion at an interface positioned on a bottom side of the cover.
 16. The cover of claim 15, wherein the closure element comprises a zipper.
 17. The cover of claim 13, wherein an interface between the top cover portion, the border panel cover portion, and at least one of the one or more internal flange elements comprises: the at least one flange element stitched to the top cover portion; and the border panel cover portion connected to the at least one flange element and the top cover portion via a tape edge connection.
 18. A method of making a mattress, the method comprising: positioning one or more internal mattress elements in an interior region of a mattress cover having an internal flange element; attaching the internal flange element to at least one of the one or more internal mattress elements; and closing the mattress cover with a closure element positioned on a bottom side of the mattress cover.
 19. The method of claim 18, further comprising forming the mattress cover, wherein forming the mattress cover comprises: attaching the internal flange element to a top cover portion with serge stitching; attaching a border panel cover portion to the internal flange element and the top cover portion with a tape edge, wherein attaching with the tape edge comprises stitching through the tape edge, the top cover portion, the internal flange element, and the border panel cover portion.
 20. The method of claim 18, wherein attaching the internal flange element to the one or more internal mattress elements comprises: attaching a hog ring to the internal flange element and to a spring; or stapling the internal flange element to a foam material. 